Removable composite insulated concrete form, insulated precast concrete table and method of accelerating concrete curing using same

Abstract

The invention comprises a concrete form. The concrete form comprises a first panel having a first primary surface for contacting plastic concrete and a second primary surface opposite the first surface, wherein the first panel is made from a rigid plastic sheet or a metal sheet; and a second panel spaced from the second primary surface of the first panel, wherein the second panel is made from a rigid plastic sheet or a metal sheet. The concrete form also comprises a layer of insulating material disposed between the first panel and the second panel. A method of using the concrete form is also disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]The present application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 61 / 822,858 filed May 13, 2013.FIELD OF THE INVENTION[0002]The present invention generally relates to a form for cement-based materials. More particularly, this invention relates to a concrete form, particularly an insulated concrete form. The present invention also relates to a method of curing concrete. The present invention also relates to a method for accelerating concrete curing using a removable insulated concrete form. The present invention also related to a method of curing concrete with reduced amounts of portland cement, which produces a concrete that cures faster and is stronger and more durable.BACKGROUND OF THE INVENTION[0003]Concrete is a composite material consisting of a mineral-based hydraulic binder which acts to adhere mineral particulates together in a solid mass; those particulates may consist of coarse aggrega...

AI Technical Summary

Benefits of technology

[0031]Another object of the present invention is to provide a concrete forming system for curing concrete that reduces or eliminates temperature shrinkage cracking associated with conventional concrete forming.

[0032]A further object of the present invention is to provide a concrete curing system that uses reduced amounts of portland cement while producing concrete

Problems solved by technology

These prior art forms are not insulated and therefore concrete is exposed to the environment.

In the next few days, most of the initial concrete moisture is also lost from the concrete.

Therefore, the two elements required to fully hydrate the cement are lost during the initial stage of concrete curing.

Thus, the cement may never fully hydrate, and, therefore, may never achieve maximum strength.

Portland cement manufacture causes environmental impacts at all stages of the process.

The production of portland cement is energy intensive, accounting for 2% of primary energy consumption globally.

Slag cement and fly ash generate relatively low amounts of heat of hydration, which result in extremely slow setting time and strength gain.

Slag cement and fly ash can be mixed with portland cement but industry practice in building construction limits use of slag cement and fly ash to no more than 30% replacement of portland cement and only during warm weather conditions.

Such concrete is also less permeable, and, therefore, structures built with slag cement and fly ash have far longer service lives.

However, only a relatively small percentage of slag is used to make slag cement in the USA.

Therefore concrete made with pozzolanic materials are seldom used due to their slower curing process.

These forms are not insulated which means that concrete is exposed to the elements during the initial portion of the curing process.

This often makes the curing of the concrete a slow process and the ultimate strength difficult to control or predict.

Initially, the hydration process produces a relatively large amount of heat.

Also, due to the heat loss to the environment the concrete placed in conventional forms does not reach its maximum potential temperature.

At the same time, moisture in the concrete is lost to the environment.

In conventional forms, both heat and moisture are lost in a relatively short time, which makes it difficult, or impossible, for the cementitious material to fully hydrate, and, therefore, the concrete may not achieve its maximum potential strength.

Therefore, heat produced within the concrete form or mold due to the hydration process usually is lost through a conventional concrete form or mold relatively quickly to the environment.

This initial relatively large temperature drop may result in significant concrete shrinkage and/or thermal effects which can lead to concrete cracking.

The remainder of the curing process is then conducted at approximately ambient temperatures, because the relatively small amount of additional heat produced by the remaining hydration process is relativ

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